Outdoor railing system and rails

ABSTRACT

An outdoor railing system has a plurality of spindles attached between upper and lower rails. Each rail includes a plurality of equally spaced recess configurations defined along the length thereof in the inwardly disposed surface for receipt of the spindle ends. Each of the recess configurations includes a first multi-sided recess having a first size and a second multi-sided recess defined within the first multi-sided recess. The second multi-sided recess is of a smaller size than the first recess for anchoring spindles having a correspondingly smaller end size.

BACKGROUND OF THE INVENTION

The present invention relates generally to railing systems especiallysuited for outdoor use, and more particularly to a top and bottom railconfiguration for such systems.

Railing systems for any number of outdoor applications are well known.For example, residential decks, pool decks, playgrounds, etc., allutilize any number of conventional railing systems. Such decking andrailing systems are typically made of pressure treated lumberparticularly suited for outdoor use. With conventional railing systems,spindles are vertically disposed between a top and bottom rail.Typically, the spindles are nailed or screwed onto the flat inwardlyfacing or side surfaces of the top and bottom rails. In order to providethe railing system with a "finished" appearance, face boards aretypically attached to the side edges thereby defining a generallyU-shaped channel with the rails into which the ends of the spindlesextend. However, this conventional configuration has significantdrawbacks. For example, the U-shaped channel is a favorite nesting placefor any manner of insects, including wasps, bees, and the like. Also,this system requires additional materials, for example the side faceboards, and is fairly labor intensive in that the spindles must first bescrewed or nailed to the top and bottom rails and then the face boardsmust be attached to the rails. This process and expense is undesirable,particularly for the residential decking industry wherein homeownersfrequently install or build their own deck systems.

With another conventional railing system, the spindles are attached tothe sides of the top and bottom rail. In other words, the spindles donot extend between the inwardly facing surfaces of the rails, but arenailed or screwed to the sides or edges of the rails. The spindlestypically include angled ends that "merge" into the sides of the rails.This conventional system also has significant drawbacks. For example,most state building or construction codes require that the rail spindlesare not spaced apart beyond a maximum distance. To attach such spindlesto the sides of the rails, the spacing must be pre-measured and markedon the rails. This disadvantage also applies to channel-railconstruction discussed above. Additionally, the spindles also have atendency to "rack" or bow with respect to the rails over time,particularly with pressure treated lumber wherein the wood tends toalternately lose and absorb moisture. The ends of the spindles tend topull away from the rails or the spindles bow and the railing systemloses its finished uniform look over time.

The present invention relates to an inexpensive and simple railingsystem that overcomes a number of disadvantages noted with prior artsystems.

OBJECTS AND SUMMARY OF THE INVENTION

It is thus a principal object of the present invention to provide animproved railing system particularly suited for outdoor use.

An additional object of the present invention is to provide rails foruse in outdoor railing systems that eliminate many disadvantages ofconventional rails.

Still an additional object of the present invention is to provideimproved prefabricated rail sections that are relatively easy toinstall.

And yet another object of the present invention is to provide improvedtop and bottom rails for outdoor railing systems that can accommodateany number of conventional spindles.

Still another object of the present invention is to provide improvedoutdoor railing system rails that help the railing system retain itsfinished appearance over a longer period of time without additionalexpense or processes in building the railing system.

In accordance with the objects and advantages of the invention, a railis provided for an outdoor railing system wherein a plurality ofvertically disposed spindles are attached to upper and lower embodimentsof the rail. The rail includes outwardly and inwardly disposed surfacesdefined along the longitudinal length thereof. The spindles are attachedto the rail along the inwardly disposed surfaces. When two such railsare used, the spindles extend between the inwardly facing surfaces ofthe rails.

A plurality of equally spaced recess configurations are defined in therails along the inwardly disposed surfaces for receipt of the spindleends. The spindle ends are anchored to the rails within the recesses.Preferably, the recesses are spaced so that the spindles are inaccordance with building or construction codes.

A unique feature of the invention is the recess configurations. Eachconfiguration includes a first multi-sided recess of a first size havingsides and a bottom surface for anchoring a spindle having an end ofcomplimentary size. Each recess configuration also includes anadditional second multi-sided recess defined within the firstmulti-sided recess. The second recess is of a smaller size than thefirst recess and also includes sides and a bottom surface for anchoringa spindle having an end of smaller complimentary size.

In this manner, the rails can accommodate a vast number of differentstyles and sizes of spindles. In other words, the rails can act as a"universal" rail for a number of spindle sizes and shapes. This is ofparticular advantage to manufacturers and retailers of railing and decksystems in that different rails need not be produced and stocked fordifferent sized spindles.

In a preferred embodiment, the second recess is defined in the bottomsurface of the first recess. The first and second recesses aremulti-sided, for example having four sides, and have a shape so as toengage at least two sides of the spindle end inserted therein. In thismanner, the spindles are prevented from twisting or racking within therecesses. It should be appreciated that it is not necessary that therecesses have an exact complimenting or matching shape as the spindleend so long as the spindles are engaged by the multi-sided recess to theextent necessary to prevent the spindles from twisting within therecesses. For example, the recesses may have a rectangular shape whereasthe spindles have square ends, or vice versa. The square ends of thespindles still fit within the recesses and will be engaged by at leasttwo sides of the recesses. In this manner, any manner of multi-sidedconfigurations is within the scope and spirit of the invention.

The first and second recesses have bottom surfaces that are preferablyflat so that a flat end of the spindle can abut against the bottomsurfaces. Likewise, the sides of the recesses may also be generally flator straight so as to engage against sides of the spindles.

Although the present rails and railing system are particularly suitedfor outdoor systems and, in this regard, are preferably formed of lumberor wood, including pressure treated lumber, the present invention is notlimited to any particular material. For example, the rails and railingsystem may be made of a plastic material, or any other suitablematerial.

It should also be appreciated that the first and second recesses neednot have the same multi-sided shape. For example, the first recess maycomprise a rectangular or square shape whereas the second recess definedwithin the first recess may comprise a triangular or other multi-sidedshape. Again, any number of configurations are within the scope andspirit of the invention.

The present invention also relates to an outdoor railing systemcomprising top and bottom rails with spindles attached between the topand bottom rails. The top and bottom rails are as described above. Therailing system according to the invention may comprise a prefabricatedlength or section having the top and bottom rails as described abovewith the spindles already anchored or attached within the recessconfigurations.

Alternatively, the present invention includes a railing system that isnot prefabricated, but is constructed on site with rails according tothe invention.

Specific preferred embodiments of the invention will be described belowthrough use of the attached figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a railing system according to theinvention with the unique top and bottom rails;

FIG. 2 is a partial perspective view of a spindle end and bottom rail;

FIG. 3 is a lengthwise partial cross-sectional view of a rail accordingto the invention particularly illustrating the recess configurations;

FIG. 4 is a cross-sectional end view taken along the lines indicated inFIG. 1;

FIG. 5 is a partial assembled view illustrating a spindle end insertedinto the second multi-sided recess;

FIG. 6 is a cross-sectional view of the embodiment illustrated in FIG. 5taken along the lines indicated;

FIG. 7 is a perspective view of a spindle end inserted into the firstmulti-sided recess; and

FIG. 8 is a cross-sectional view of the embodiment of FIG. 7 taken alongthe lines indicated.

DETAILED DESCRIPTION

Reference will now be made in detail to the presently preferredembodiments of the invention, one or more examples of which areillustrated in the drawings. Each example is provided by way ofexplanation of the invention, and not meant as a limitation of theinvention. For example, features illustrated or described as part of oneembodiment can be used on another embodiment to yield still a thirdembodiment. It is intended that the present invention include suchmodifications and variations as come within the scope and spirit of thepresent invention.

FIG. 1 illustrates a railing system, generally 10, according to theinvention. Railing system 10 is illustrated only as a section of arailing system for purposes of illustration. It should be understoodthat the present invention includes a complete railing system, as wellas pre-fabricated sections of a railing system that may be manufacturedand sold in standard lengths. Such pre-fabricated railing sections areparticularly popular in the residential home decking industry.

It should also be appreciated that the present invention is not limitedto any particular type of material. Although most outdoor decking andrailing systems are conventionally made of lumber, for example pressuretreated lumber, the present invention is not limited to wood or lumber.The components of the rails and railing system may be made of anyconstruction material, for example a plastic material, cementiousmaterial, etc. Any and all such materials are within the scope andspirit of the invention.

Railing system 10 according to the invention utilizes a unique top orbottom rail, generally 12. Preferably, the railing system 10incorporates a top rail 36 and a bottom rail 38 that are essentiallyidentical. In this regard, the present invention also includes either ofthe top rail or bottom rail as a separate component that may bemanufactured or sold separate from a pre-fabricated rail section for usein a railing system.

When constructed, railing section 10 includes top rail 36, and bottomrail 38 having a plurality of spindles 14 attached between the inwardlyfacing surfaces 20 of the top and bottom rails. Each rail also includesan outwardly facing surface 18 and side edges 42. A decorative profilemay be defined on side edges 42. As generally illustrated in FIG. 1, thetop and bottom rails 36, 38 include a plurality of generally equallyspaced recess configurations, generally 22, defined along thelongitudinal length thereof in the inwardly facing surfaces 20. The ends16 of the spindles are inserted into and anchored relative to rails 12by way of recess configurations 22.

FIGS. 2 and 3 illustrate the recess configurations 22 in greater detail.Each recess configuration includes a first multi-sided recess 24 and asecond multi-sided recess 30 defined within first multi-sided recess 24.For example, in the embodiment illustrated in FIGS. 2 and 3, firstmulti-sided recess 24 is defined by sides 26 and a bottom surface 28.First multi-sided recess 24 has a first size for accommodating ends 16of spindles 14 having a complimenting size. It should be appreciatedthat end 16 need not have an exact matching shape of the multi-sidedrecess. For example, multi-sided recess 24 may be rectangular whereasend 16 of the spindle is square so long as at least two sides of end 16abut against sides 26 of recess 24 to lock end 16 within recess 24. Inthis regard, it should be appreciated that multi-sided recess 24 cantaken on any number of multi-sided configurations. FIGS. 4, 7, and 8illustrate attachment of a relatively larger sized spindle end 16 with afirst multi-sided recess 24.

Second multi-sided recess 30 is defined within first multi-sided recess24 and includes a bottom surface 34 and sides 32. Thus, bottom surface28 of first recess 24 defines the top plane of second multi-sided recess30. Second multi-sided recess 30 thus has a smaller size than firstmulti-sided recess 24 for accommodating spindle ends of a lesser orsmaller size. This concept is particularly illustrated in FIGS. 5 and 6.

Preferably, the respective sides and bottoms of recesses 24, 30 aregenerally flat so that correspondingly flat sides and bottoms of spindleends 16 can abut against these surfaces for secure anchoring of thespindles. The spindles may be further anchored within the recesses byconventional screws 40, adhesives, nails, etc.

It should be understood that the first and second multi-sided recesses24, 30 do not necessarily need to have the same shape or configuration,although for ease of manufacturing this may be preferred. For example,the first multi-sided recess 24 may be rectangular whereas secondmulti-sided recess 30 may be square and vice versa.

Preferably, the plurality of recess configurations 22 are spaced apartalong the length of rails 12 so as to meet restrictive codes. In thisway, the rails need not be measured for placement of the spindles 14.

Once the spindle ends 16 are anchored within either of the multi-sidedrecesses 24, 30, they are prevented from twisting or torquing relativeto top and bottom rails 36, 38 and the rail system 10 retains aprofessional finished appearance over a longer period of time. Also, asseen in FIG. 1, ends 16 of spindles 14 extend into recess configurations22 so as to give the rail system 10 a "finished" appearance without thenecessity of attaching additional face strips or boards along edges 42.This significantly cuts back in material, expenses, and labor.

The exact depth and dimensions of recesses 24, 30 are not particularlycritical so long as the recesses have a sufficient depth to accommodatespindles ends 16 taking into account shrinkage and expansion of thespindles over time as they tend to lose and absorb moisture. Likewise,the depth should not be so great so as to weaken the structuralintegrity of rails 12.

It should be appreciated by those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the scope and spirit of the invention. Forexample, the first and second recesses may have any number ofmulti-sided configurations to prevent the spindle ends from twisting ortorquing within the recesses. Likewise, the rails and railing system maybe made of any conventional construction material. It is intended thatthe present invention include such modifications and variations as comewithin the scope of the appended claims and their equivalents.

What is claimed is:
 1. A rail for an outdoor railing system wherein aplurality of vertically disposed spindles are attached to an upper andlower of said rail, said rail comprising:outwardly and inwardly disposedsurfaces defined along a longitudinal length thereof, wherein spindlesare attachable along said inwardly disposed surface; a plurality ofgenerally equally spaced recess configurations defined in said railalong said inwardly disposed surface for receipt of spindle ends toanchor the spindles to said rail; each of said recess configurationsfurther comprising a first multi-sided recess of a first size havingsides and a bottom surface for anchoring a spindle having an end ofcomplementary size; and each of said recess configurations furthercomprising a second multi-sided recess defined within said firstmulti-sided recess, said second recess being of a smaller size than saidfirst recess and having sides and a bottom surface for anchoring aspindle having an end of complementary size.
 2. The rail as in claim 1,wherein said second recess is defined in said bottom surface of saidfirst recess.
 3. The rail as in claim 1, wherein said first and secondrecesses have four sides.
 4. The rail as in claim 1, wherein said firstand second recess bottom surfaces are generally flat so that a spindleend can abut against said bottom surfaces.
 5. The rail as in claim 1,wherein said rail is made of wood.
 6. The rail as in claim 5, whereinsaid rail is made of pressure treated wood particularly suited foroutdoor use.
 7. The rail as in claim 1, wherein said rail can be used asa top or bottom rail in a railing system.
 8. The rail as in claim 1,wherein said first and second recesses have a shape so as to engagespindle ends inserted therein along at least two sides so as to preventthe spindles from twisting within said recesses.
 9. An outdoor railingsystem, comprising:a top rail and a bottom rail with a plurality ofgenerally equally spaced spindles attached between said top and saidbottom rails; each of said top and bottom rails furthercomprisingoutwardly and inwardly disposed surfaces defined along alongitudinal length thereof, wherein said spindles are attached alongsaid inwardly disposed surface; a plurality of generally equally spacedrecess configurations defined in said top and bottom rails along saidinwardly disposed surfaces for receipt of ends of said spindles toanchor said spindles to said rails; each of said recess configurationsfurther comprising a first multi-sided recess of a first size havingsides and a bottom surface for anchoring said spindles having an end ofcomplementary size; and each of said recess configurations furthercomprising a second multi-sided recess defined within said firstmulti-sided recess, said second recess being of a smaller size than saidfirst recess and having sides and a bottom surface for anchoring saidspindles of a smaller complementary size.
 10. The railing system as inclaim 9, wherein said system comprises a pre-fabricated length of saidtop and bottom rails with said spindles anchored within said recessconfigurations.
 11. The railing system as in claim 9, wherein saidsecond recess is defined in said bottom surface of said first recess.12. The railing system as in claim 9, wherein said spindles are engagedagainst at least two said sides of said first or second recess so thatsaid spindles are prevented from twisting within said respective recess.13. The railing system as in claim 12, wherein said recesses comprisefour sides.
 14. The railing system as in claim 9, wherein said first andsecond recess bottom surfaces are generally flat so that said spindlesabut against said bottom surfaces.
 15. The railing system as in claim 9,wherein said top and bottom rails and said spindles are made of wood.16. The railing system according to claim 1 wherein the firstmulti-sided recess further comprises a recess having at least three sidewalls.
 17. The railing system according to claim 9 wherein the firstmulti-sided recess further comprises a recess having at least three sidewalls.